Delta Smart Manufacturing Solutions helping to fully upgrade industries

“Industry 4.0” is a term first coined by the CEO and science director of the German Research Center for Artificial Intelligence (DFKI), Wolfgang Wahlster, in 2011. In 2013, Ulrich Sendler published the book “Industry 4.0”, officially starting the industry 4.0 age. This was the prelude to today’s revolution of smart production in manufacturing industries worldwide. Several nations have also published similar literature, each with their own methods, but the key behind it all is smart production.

By 2013, Delta had accumulated more than 50 years of experience in manufacturing and 20 years of knowledge in industrial automation. Delta has actively invested in smart production and hopes to automate, smarten, and digitize its competitiveness in manufacturing. Based on successful cases in Delta’s own factories and for clients, Delta has launched smart machines, visualized manufacturing management, smart production management, smart factories, energy management, and other smart production solutions, helping companies construct smart, green factories, and fully upgrading existing industries.


Smart production full environment diagram.

Smart machines: Delta's complete industrial product line—from sensing instruments, to transmission and motion systems, control equipment, network equipment, robots, and others—are all complete products. These products are the basis for ensuring full equipment automation, so that the machine offers high precision, complete control functions, and analysis and sensing functions. Delta Smart Machines are widely used in textile, printing, packaging, electronics manufacturing, automotive components, and other industries to help companies achieve automation and smart production processes.

Manufacturing visualized management: Clients can use Delta's network management switch to construct a decentralized and stable network system. They can then use DIALink to download the equipment and equipment data, and share the information to the management's upper software to create manufacturing visualization and achieve layered information diversion. The data is analyzed using the Delta Manufacturing Visualization Management Platform, which helps a company transparently process the production data, grasp the production progress status at a glance, manage the production quality, conduct a production efficiency analysis, and track the product resume. It is also possible to grasp the real-time status of the equipment through the platform, notify the relevant personnel to repair abnormal equipment, and analyze the abnormal KPI data of the equipment to deal with any malfunctions more specifically. Taking a project in Dongguan as an example, Delta solutions helped customers monitor the operating status of the equipment in real time, instantly measure key parameters (temperature, pressure) of the equipment, and automatically generate a data package table. The specific benefits are to save construction and maintenance costs, improve yield, and maximize production capacity by controlling and monitoring key parameters.

Smart manufacturing management system: The manufacturing execution system is the execution layer between the planning layer and the on-site equipment layer. It is mainly responsible for workshop production management and scheduling execution. A complete MES system can integrate management functions such as production scheduling, process tracking, quality control, equipment failure analysis, and report analysis on a unified platform. Manufacturing departments, QC departments, technical department, and logistics department can use it to provide workshop management information services through a unified database and network connection. The system helps companies implement complete closed-loop production by emphasizing the overall optimization of the manufacturing process, and establishing an integrated and up-to-date ERP/MES/SFC information system. MES not only features manufacturing execution functions, but also features an open API, which enables a seamless interface with third-party systems, realizes data sharing, automation, and information integration, and makes it the core of a digitized factory.

Smart factory monitoring system: This is mainly based on factory auxiliary systems, such as plantheating, water treatment, waste treatment, air compression, refrigeration station, and environmentalcontrol (temperature and humidity, sterile dust-free treatment). These are the basics for stableproduction in the factory. Once a chemical leak occurs, inadvertent power loss occurs, or the temperatureand humidity environment is unstable, the production chain will be broken. Through the DIAViewSCADA software, the factory monitoring system centrally monitors the plant equipment to instantlyunderstand the operational status of the plant system, eliminate hidden dangers in the equipment, andautomatically adjust the operating status in real time to ensure that production demands are met.

Energy management system: Delta offers a complete energy management system solution, fromensuring energy efficient equipment with advanced automation technology and energy-saving products, tomaking production and factory equipment more energy efficient. This system identifies the mostimportant energy-consuming equipment, and uses energy-saving equipment such as variable-frequencydrives to reduce energy consumption and improve the efficiency of machine equipment. Energy efficiencyof the system is managed from the perspective of the production line. The energy consumption on theproduction line is highly variable, and the rational management of energy at different times on theproduction line is key. Finally, energy efficiency is managed based on the layout of the whole plant. Allenergy consumption data in the factory is transmitted to the industrial energy management system forvisual monitoring and analysis. This provides the basis for formulating energy-saving measures andsolutions and ultimately improving efficiency and utilization of energy management. The energymanagement system has been verified by many users, and energy saving efficiency is more than25% with a return on investment within less than 2 years.

Overview of smart manufacturing solutions

Another core value of smart manufacturing is resolving company problems. Some companies seek to improve their products, while other companies wish to digitize design production and management. There are also companies that are actively planning energy-saving factories. Delta smart production allows companies to solve problems by choosing the appropriate package for their situation. At the same time, Delta smart production solutions are based on a big picture perspective, covering long term planning and assisting companies fully upgrade their industries.